Exhaust component, method for producing such an exhaust component, and device for carrying out said method

ABSTRACT

An exhaust-gas component, having a—cross-sectionally—rectangular arrangement composed of at least one—cross-sectionally—rectangular exhaust-gas aftertreatment element; and a housing which engages around the—cross-sectionally—rectangular arrangement. The housing has a rectangular cross section and is divided, along a diagonal of the cross section, into two housing parts. The housing is arranged under compressive stress in an external housing.

The invention relates to an exhaust-gas component, to a method for producing an exhaust-gas component of said type, and to a device for carrying out a production method of said type.

US 2011/0030355 A1 has disclosed an exhaust-gas component which has a multiplicity of—cross-sectionally—rectangular exhaust-gas aftertreatment elements. The exhaust-gas component has a housing which engages around the exhaust-gas aftertreatment elements which—cross-sectionally—are arranged relative to one another so as to form a rectangular arrangement, wherein the housing has a rectangular cross section and is divided, along a diagonal of the cross section, into two housing parts. The two housing parts are welded to one another. A disadvantage here is that the production of the exhaust-gas component is cumbersome owing to the welding of the housing parts, wherein said housing parts are rigidly fixed to one another by means of the weld seam connection. Dismantling of the exhaust-gas component—for example for maintenance or exchange purposes, for example for replacement of an exhaust-gas aftertreatment element—is scarcely possible, or is possible only with great effort.

The invention is based on the object of creating an exhaust-gas component, a method for producing an exhaust-gas component of said type, and a device for carrying out a production method of said type, wherein the stated disadvantages do not arise.

The object is achieved through the creation of the subjects of the independent claims. Advantageous refinements emerge from the subclaims.

The object is achieved in particular in that an exhaust-gas component is created, which has at least one—cross-sectionally—rectangular exhaust-gas aftertreatment element, preferably a multiplicity of—cross-sectionally—rectangular exhaust-gas aftertreatment elements, and has a housing which engages around the exhaust-gas aftertreatment elements which—cross-sectionally—are arranged relative to one another so as to form a rectangular arrangement or around the at least one—cross-sectionally—rectangular exhaust-gas aftertreatment element, which in this case individually forms a cross-sectionally rectangular arrangement, wherein the housing has a rectangular cross section and is divided, along a diagonal of the rectangular cross section, into two housing parts. Here, it is provided that the housing is arranged under compressive stress in an external housing. By virtue of the fact that the housing parts are not welded to one another but are arranged under compressive stress in the external housing, an assembly process of the exhaust-gas component is greatly simplified. The housing parts are however preferably welded to the external housing, in particular by means of in each case one weld seam per housing part. For maintenance and/or exchange purposes, the housing can be easily—possibly after the detachment of a weld—removed from the external housing, for example by being pulled out, resulting in a fast, simple and inexpensive exchange of exhaust-gas aftertreatment elements or of the entire housing including the exhaust-gas aftertreatment elements.

The housing parts are preferably forced toward one another under stress at mutually adjacent housing edges. They are in particular not rigidly connected to one another, but rather arranged in the external housing under elastic prestress.

An exhaust-gas component is to be understood in particular to mean a device which is configured for exhaust-gas aftertreatment in an exhaust-gas-conducting line system, in particular an exhaust-gas tract, more particularly of an internal combustion engine. Here, the exhaust-gas component has in particular a casing, in this case in particular the external housing, which preferably simultaneously has connection points for integration into an exhaust-gas tract, in particular for the supply and discharge of exhaust gas. Furthermore, the exhaust-gas component can be handled by way of its casing. The exhaust-gas component is in particular configured for performing a particular exhaust-gas aftertreatment, and is designed for example as an oxidation catalytic converter, as an SCR catalytic converter for the selective catalytic reduction of nitrogen oxides, or as a particle filter. An exhaust-gas component may however also exhibit more than one such function.

An exhaust-gas aftertreatment element is in particular a device which is configured specifically for performing a particular exhaust-gas aftertreatment, wherein it is simultaneously configured for arrangement and use in an exhaust-gas component. The exhaust-gas aftertreatment element preferably has a substrate body and a catalytically active coating arranged on the substrate body. The substrate body is preferably a ceramic body, in particular a ceramic catalyst substrate. The catalytically active coating may for example be an oxidation catalyst or an SCR catalyst suitable for the selective catalytic reduction of nitrogen oxides. The exhaust-gas aftertreatment element may also be formed as a particle filter element, wherein, in this case, it preferably has a porous filter body, in particular a porous ceramic body as filter body.

The housing, which is arranged under compressive stress in the external housing, is formed in particular as an internal housing. Altogether, the exhaust-gas component thus preferably has an internal housing, which itself has two housing parts, and an external housing, which in the assembled state engages around the internal housing, wherein the internal housing is arranged under compressive stress in the external housing.

“Compressive stress” is to be understood in particular to mean that the arrangement composed of the housing, specifically the two housing parts, and the at least one exhaust-gas aftertreatment element—which is also referred to as compression unit—is of elastically flexible design, wherein in particular, the housing parts can be forced inward elastically toward one another and toward the at least one exhaust-gas aftertreatment element or the multiplicity of exhaust-gas aftertreatment elements, which is referred to as compression. The housing parts of the housing are thus displaced further toward one another, and in particular displaced further inward, under compressive stress than in a stress-relieved state in which no forces act which give rise to compression of the arrangement composed of the housing parts and the exhaust-gas aftertreatment elements. The elasticity of the arrangement may result in particular from the characteristics, in particular shape and/or material characteristics, of the housing parts, from the geometrical arrangement of the housing parts relative to one another, and/or from additionally provided compression elements, in particular compression mats.

The housing parts preferably have a wall thickness of at least 0.5 mm to at most 1.5 mm, in particular of 1 mm, whereby they have a resilient, elastic form.

The statement that the housing parts are forced toward one another under stress at mutually adjacent housing edges means in particular that housing edges of the housing parts exist which extend perpendicular to a cross-sectional plane of the exhaust-gas component and which face one another where the diagonal of the cross section divides the housing into the two housing parts, in particular where a diagonal plane, in which the corresponding diagonal runs, intersects the cross-sectional plane. The housing parts are preferably dimensioned such that, in the assembled but non-compressed state of the exhaust-gas component, the housing edges have a spacing to one another, wherein said housing edges can be forced against one another or toward one another by compression of the exhaust-gas component. It is possible here for said housing edges to make contact with one another in the compressed state, though it is also possible for the housing edges to still have a spacing to one another even in the compressed state, which spacing is however smaller than in the stress-relieved state.

A cross section is to be understood here to mean a view of the exhaust-gas component and/or of a part or element of the exhaust-gas component in a plane to which a longitudinal direction of the exhaust-gas component is perpendicular. Here, the longitudinal direction of the exhaust-gas component is in particular a direction along which the exhaust-gas component is flowed through by an exhaust-gas flow during operation. In particular, a flow path of the exhaust gas extends through the exhaust-gas aftertreatment elements from an upstream face side to a downstream face side thereof in the longitudinal direction.

The housing and in particular also the exhaust-gas component as a whole is/are preferably of cuboidal form. It is alternatively or additionally preferably provided that the exhaust-gas aftertreatment elements are of cuboidal form. Here, a longest edge of such a cuboid extends preferably in the longitudinal direction, wherein shorter edges of the cuboid extend in the cross-sectional plane. It is possible for the exhaust-gas component and/or the exhaust-gas aftertreatment elements to have a square cross section, wherein the two shorter edges, which are shorter than the longest edge, are preferably of equal length.

It is also possible for different exhaust-gas aftertreatment elements to have different geometries, such that, for example, a first exhaust-gas aftertreatment element may have a square cross section and a second exhaust-gas aftertreatment element may have a rectangular, non-square cross section.

An edge length of the housing preferably amounts to an integer multiple of an edge length of an exhaust-gas aftertreatment element, wherein this includes the factor 1. In particular, it is possible for only one exhaust-gas aftertreatment element to be provided in the housing as viewed in the longitudinal direction, wherein at least one, two or more exhaust-gas aftertreatment element(s) is/are arranged along at least one transverse direction. It is additionally or alternatively possible for more than one exhaust-gas aftertreatment element to be arranged one behind the other as viewed in the longitudinal direction.

The exhaust-gas component preferably has a multiplicity of exhaust-gas aftertreatment elements of identical form, in particular of geometrically identical form. These preferably individually cuboidal exhaust-gas aftertreatment elements may then in turn be assembled to form an altogether cuboidal arrangement by virtue of the exhaust-gas aftertreatment elements being arranged adjacent to one another and/or one behind the other. The housing then preferably has corresponding edge lengths which correspond to the corresponding single or multiple exhaust-gas aftertreatment element(s) along the various directions.

The external housing preferably also has corresponding edge lengths.

The external housing is furthermore preferably dimensioned such that the compression unit can be arranged under compressive stress in the external housing. For this purpose, in particular, in accordance with the desired compressive stress, the external housing has external edges which are selected to be smaller than the external edges of the compression unit composed of the housing parts and the exhaust-gas aftertreatment elements in the stress-relieved state.

In one refinement of the invention, it is provided that the housing parts are formed as—cross-sectionally—L-shaped sheet-metal elements. In particular, the housing parts are preferably formed as angularly folded sheet-metal shell halves. The housing parts can in this case be produced particularly easily and quickly and inexpensively. An edge length, measured in the longitudinal direction, of the sheet-metal shell halves preferably amounts approximately to an integer multiple of a corresponding edge length of the exhaust-gas aftertreatment elements; an edge length, measured in the cross-sectional plane, of the sheet-metal shell halves preferably amounts to an integer multiple of a corresponding edge length of the exhaust-gas aftertreatment elements, wherein the integer multiple relates in particular to the number of exhaust-gas aftertreatment elements actually arranged along a particular direction in the arrangement. Here, an integer multiple also includes the factor 1.

An edge length, measured in the cross-sectional plane, of a housing edge of at least one of the housing parts is preferably smaller than a length of an arrangement edge, bearing against said housing edge in the assembled state, of the arrangement of the at least one exhaust-gas aftertreatment element or of the exhaust-gas aftertreatment elements in the stress-relieved state. These are not the housing edges which are adjacent to one another or displaced toward one another during the compression, but rather the housing edges oriented perpendicular thereto, which are arranged parallel to the arrangement edges, lying in the cross-sectional plane, of the arrangement of exhaust-gas aftertreatment elements. The fact that said housing edges have a smaller edge length than the arrangement edges results in a spacing between the housing edges running perpendicular to the cross-sectional plane, which are forced toward one another in the compressed state. The corresponding configuration thus specifically permits a compression of the arrangement with displacement of the housing parts toward one another.

In one refinement of the invention, it is provided that the housing parts have positive-locking elements at those housing edges which are mutually adjacent in the assembled state, wherein the positive-locking elements are configured to engage one into the other in the assembled state. Here, the positive-locking elements are particularly preferably designed such that they engage one into the other already in the non-compressed state, that is to say in the stress-relieved state. In this way, the housing parts can be aligned relative to one another by means of the positive-locking elements. Here, the positive-locking elements are designed such that they can engage more deeply in the compressed state, such that the housing parts can be displaced toward one another.

In one refinement of the invention, it is provided that at least one compression mat is arranged between at least one exhaust-gas aftertreatment element and the housing. Alternatively or in addition, at least one compression mat is preferably arranged between at least two exhaust-gas aftertreatment elements. Said compression mats serve firstly for sealing off the exhaust-gas component with regard to the exhaust-gas flow passing through it during operation, and secondly, such compression mats—preferably in addition to the elastic configuration of the housing parts—provide elasticity for the compression unit of the exhaust-gas aftertreatment elements, of the housing parts and of the compression mats. A compression mat of said type is preferably arranged at least in regions between each exhaust-gas aftertreatment element and an exhaust-gas aftertreatment element adjacent thereto, wherein it is furthermore preferable for a compression mat to be arranged at least in regions between each exhaust-gas aftertreatment element and a housing part adjacent thereto. In this way, particularly good compressibility with simultaneously optimized gas impermeability for the arrangement is achieved.

In one refinement of the invention, it is provided that a multiplicity of identical compression mats are provided, wherein each compression mat has at least one slot, wherein preferably, at least two compression mats are arranged so as to be fitted one into the other. This represents a particularly simple configuration of the compression mats, because these can be manufactured as identical parts. Furthermore, the compression mats can be easily arranged in the exhaust-gas component by being fitted together and placed between or onto the exhaust-gas aftertreatment elements. In particular, no complicated wrapping of exhaust-gas aftertreatment elements with compression mats is necessary.

It is particularly preferable for at least two compression mats to be arranged so as to be fitted one into the other by way of their slots. In particular, it is possible for the compression mats to have a middle, central slot which extends preferably from one mat edge into the compression mat over a certain region, for example approximately as far as a center of the compression mat, wherein two compression mats are arranged in a cross-shaped manner and preferably perpendicularly with respect to one another and can be fitted one into the other by way of their central slots. Such an arrangement of compression mats is suitable in particular for a central, middle arrangement in the exhaust-gas component between the exhaust-gas aftertreatment elements.

The compression mats preferably have in each case one central slot and two lateral recesses which are open to the edge, and which extend in regions along mat edges of the compression mats. A remaining region of the edges then forms, as it were, a projection relative to the position of the mat edge in the region of the recess. The compression mats are preferably arranged such that they engage one into the other by way of their slots and/or by way of the projections and recesses. In particular, it is possible, as already described, for two mats to be arranged in a cross-shaped manner in the center between four exhaust-gas aftertreatment elements, wherein said mats engage one into the other by way of their central slot. Additionally or alternatively, it is possible for in each case at least one compression mat to be arranged at the outside on an outer side of the arrangement of exhaust-gas aftertreatment elements, wherein the compression mats arranged on adjacent or adjoining sides engage in each case with a projection into a recess of the adjacent mat. For this purpose, the laterally adjacently arranged compression mats are preferably arranged in different orientations, such that in each case one projection overlaps a recess.

In one refinement of the invention, it is provided that the housing parts have face-side, inwardly directed housing flanges. Here, a face side refers to a side which is oriented parallel to a cross-sectional plane and to which, in particular, a main flow direction of exhaust gas during the operation of the exhaust-gas component is perpendicular. The face-side, inwardly directed housing flanges of the housing parts can be particularly easily and expediently utilized for applying to the housing parts, or introducing into the housing parts, pressing-in forces for the pressing of the housing with the arrangement of the at least one exhaust-gas aftertreatment element into the external housing.

The housing parts preferably additionally or alternatively have in each case at least one pull-out element which is designed for the housing parts together with the arrangement of the exhaust-gas aftertreatment elements to be pulled out of the external housing by means of the pull-out element, in particular for the purposes of maintenance or exchange of the exhaust-gas aftertreatment elements and/or for the purposes of handling the exhaust-gas component—in particular by means of a crane. The pull-out elements are preferably configured as eyelets which may be arranged in particular at the folded edges of the angular housing parts formed as sheet-metal shell halves, preferably welded there.

The housing parts are preferably welded to the external housing in the region of the pull-out elements, in particular between a respective pull-out element and the external housing, by means of in each case one weld seam preferably 50 mm in length.

The housing flanges preferably have apertures for the pull-out elements, or extend only over a length which leaves space free for the pull-out elements.

In one refinement of the invention, it is provided that the external housing has external-housing flanges which are directed outward at a face side and which have flange positive-locking elements. Said external-housing flanges are preferably provided for the arrangement of the external housing itself in a superordinate exhaust-gas housing and for the fastening of said external housing therein. In particular, it is possible for a multiplicity of external housings to be arranged in a superordinate exhaust-gas housing of said type. Here, the flange positive-locking elements serve for the alignment of the different external housings relative to one another in order that they can be arranged more closely together and structural space can thereby be saved. For this purpose, the flange positive-locking elements are preferably formed as a sequence of projections and recesses along edges of the external-housing flanges, wherein these are formed and/or oriented such that adjacent external housings can in each case engage with their projections and recesses one into the other. In particular, it is possible for the configuration with regard to the arrangement of the projections and recesses on a first external-housing flange to be complementary with respect to a corresponding configuration on a second external-housing flange arranged on an opposite side as viewed in cross section, such that identical external housings arranged adjacent to one another at one of said sides can engage with the projections and recesses of their external-housing flanges one into the other.

The configuration of the external-housing flanges with projections and recesses furthermore saves material in the flange region.

The object is also achieved through the creation of a method for producing an exhaust-gas component, wherein an exhaust-gas component according to one of the above-described exemplary embodiments is preferably produced in the context of the method. The method has the following steps: a—cross-sectionally—L-shaped first housing part is provided. At least one—cross-sectionally—rectangular, preferably square, exhaust-gas aftertreatment element or a multiplicity of—cross-sectionally—rectangular, preferably square, exhaust-gas aftertreatment elements is/are arranged on the first housing part to form a—cross-sectionally—rectangular, preferably square, arrangement. A—cross-sectionally—L-shaped second housing part is placed onto the arrangement of the exhaust-gas aftertreatment element or the exhaust-gas aftertreatment elements. In this way, a compression unit is produced. Said compression unit has the first housing part, the arrangement of at least one exhaust-gas aftertreatment element, preferably—as will be discussed in more detail—at least one compression mat, and the second housing part. A compression force is applied to the housing parts such that the compression unit is compressed. Here, a compression of the compression unit is to be understood in particular to mean that the housing parts are forced with mutually adjacently arranged housing edges against one another or toward one another under stress. The compression unit is then pressed under compressive stress into an external housing. In particular, the advantages that have already been discussed in conjunction with the exhaust-gas component are attained in conjunction with the method.

In one refinement of the invention, it is provided that at least one compression mat is arranged between at least one exhaust-gas aftertreatment element and at least one housing part, and/or between at least two exhaust-gas aftertreatment elements. A multiplicity of compression mats is preferably used, wherein, in particular, compression mats are arranged between adjacent exhaust-gas aftertreatment elements and between the exhaust-gas aftertreatment elements and housing parts adjacent thereto.

In one refinement of the invention, it is provided that the first housing part is arranged on a holding device, wherein the holding device has a—cross-sectionally —L-shaped support surface. Here, the first housing part is in particular arranged on the support surface. A tip—or a knee—of the L-shaped support surface preferably points downward—as viewed in the direction of gravitational force—such that that the first housing part can be arranged in a secure, stable and fixed manner on the support surface.

It is possible for the first housing part to be placed directly onto the support surface. In this case, the support surface preferably has at least one recess for the arrangement of at least one clamping bracket in the support surface or below the support surface. The clamping bracket can thus initially be arranged below the first housing part, wherein the housing parts can later be clamped by means of the clamping bracket. It is alternatively possible for at least one clamping bracket to be arranged on the support surface, wherein the first housing part itself is arranged on the at least one clamping bracket. Here, the first housing part is arranged directly on the support surface. In this case, too, the clamping bracket is arranged under the first housing part and can later be used for the clamping of the compression unit.

It is particularly preferable for two clamping brackets to be used which are arranged spaced apart from one another as viewed in the longitudinal direction, which permits particularly stable clamping of the housing parts.

It is possible for at least one first clamping bracket part to initially be arranged on or in the support surface, in particular a first clamping bracket half, which is later completed by means of a second clamping bracket part or a second clamping bracket half to form a clamping bracket which engages around the compression unit along its entire circumference. The clamping can in this case be applied in particular by virtue of the two clamping bracket parts or clamping bracket halves being braced together. It is particularly preferable here for in each case two clamping bracket parts or clamping bracket halves to be used, such that, in particular, there are two resulting clamping brackets. A clamping bracket part of said type or a clamping bracket half is preferably of L-shaped configuration.

A refinement of the invention is preferred in which it is provided that the compression force is applied to the housing parts by means of at least one clamping bracket clamped around the compression unit, preferably by means of a multiplicity of clamping brackets clamped around the compression unit, in particular by means of two clamping brackets.

Here, the clamping brackets are preferably designed as has already been discussed above.

The at least one clamping bracket preferably has at least one clamping stop which prevents excessive compression as a result of excessively intense clamping of the clamping bracket. The clamping stop is preferably formed or arranged on at least one clamping bracket part.

It is possible for the compressed compression unit with the clamping brackets to initially be inserted at the end side into the external housing, wherein the compression unit is then pressed out of the clamping brackets and into the external housing. It is alternatively possible, after the compression unit has been inserted at the end side into the external housing, for the clamping brackets to be—preferably successively—released as the compression unit is pressed into the external housing. A release of the clamping brackets may be performed in particular when the compression unit is already securely held in its compressed position by the external housing, such that said compression unit cannot fall apart.

In one refinement of the invention, it is provided that the compression unit is pressed into the external housing by application of a pressing force to face-side, inwardly directed housing flanges of the housing parts. As already described, the housing flanges can be easily and advantageously utilized for introducing a corresponding pressing force into the compression unit.

The object is also achieved through the creation of a device for carrying out a method according to one of the embodiments described above. Said device has a holding device with a—cross-sectionally—L-shaped support surface, and furthermore has at least one clamping bracket for applying a compression force to the housing parts. The device is preferably designed as has already been discussed in conjunction with the method. Here, in particular, the advantages that have already been discussed in conjunction with the method and the exhaust-gas component are attained.

The device preferably has at least one stop element for the alignment of the housing parts, of the exhaust-gas aftertreatment elements and/or of the compression mats.

The device preferably has a press device for pressing the compression unit into the external housing.

The device preferably has two clamping brackets. The at least one clamping bracket preferably has two clamping bracket parts or clamping bracket halves that can be braced together.

In one refinement of the invention, it is provided that the clamping bracket can be arranged with a first clamping bracket part on the support surface, or that the support surface has at least one recess for at least one first clamping bracket part of the clamping bracket. It is particularly preferable for two clamping brackets to be arrangeable with in each case one first clamping bracket part on the support surface, or for the support surface to have two recesses for two clamping bracket parts. In general, depending on a length of the exhaust-gas component, it is also possible for more than two clamping brackets to be used.

Finally, the invention also includes an internal combustion engine which has an exhaust-gas component according to one of the exemplary embodiments described above. In particular, the advantages that have already been discussed in conjunction with the exhaust-gas component are attained in conjunction with the internal combustion engine. Here, the exhaust-gas component is designed and arranged for the aftertreatment of exhaust gas of the internal combustion engine.

The internal combustion engine is preferably in the form of a reciprocating-piston engine. It is possible for the internal combustion engine to be designed for driving a passenger motor vehicle, a heavy goods motor vehicle or a utility vehicle. In a preferred exemplary embodiment, the internal combustion engine serves for driving in particular heavy land vehicles or watercraft, for example mining vehicles and trains, wherein the internal combustion engine is used in a locomotive or in a power car, or ships. Use of the internal combustion engine for driving a vehicle used for defense purposes, for example a tank, is also possible. An exemplary embodiment of the internal combustion engine is preferably also used in a static situation, for example for static energy supply for emergency-power operation, continuous-load operation or peak-load operation, wherein the internal combustion engine in this case preferably drives a generator. A static use of the internal combustion engine for driving auxiliary assemblies, for example fire extinguishing pumps on drilling platforms, is also possible. A use of the internal combustion engine in the field of the conveyance of fossil resources and in particular fuels, for example oil and/or gas, is furthermore possible. A use of the internal combustion engine in the industrial sector or in the construction sector, for example in a construction or building machine, for example in a crane or in a digger, is also possible. The internal combustion engine is preferably in the form of a diesel engine, a gasoline engine, a gas engine for operation with natural gas, biogas, special gas or some other suitable gas. In particular if the internal combustion engine is in the form of a gas engine, it is suitable for use in a cogeneration plant for static energy generation.

The description of the exhaust-gas component, of the device for carrying out the method and of the internal combustion engine, on the one hand, and of the method, on the other hand, are to be understood as being complementary to one another. Features of the exhaust-gas component, of the device and of the internal combustion engine that have been described explicitly or implicitly in conjunction with the method are preferably, individually or in combination with one another, features of a preferred exemplary embodiment of the exhaust-gas component, of the device and/or of the internal combustion engine. Method steps that have been described explicitly or implicitly in conjunction with the exhaust-gas component, with the device and/or with the internal combustion engine are preferably, individually or in combination with one another, steps of a preferred embodiment of the method. Said method is preferably characterized by at least one method step which is conditional on at least one feature of an exemplary embodiment according to the invention, or preferred exemplary embodiment, of the exhaust-gas component, of the device and/or of the internal combustion engine. The exhaust-gas component, the device and/or the internal combustion engine is/are preferably characterized by at least one feature which is conditional on at least one method step of an embodiment according to the invention, or preferred embodiment, of the method.

The invention will be discussed in more detail below on the basis of the drawing, in which:

FIG. 1 shows an exploded illustration of an exemplary embodiment of an exhaust-gas component with assembled compression unit and external housing;

FIG. 2 shows an illustration of the exemplary embodiment of the exhaust-gas component as per FIG. 1 in an assembled state;

FIG. 3 shows an illustration of the arrangement of compression mats on the exemplary embodiment of the exhaust-gas component as per FIG. 1;

FIG. 4 shows an illustration of an exemplary embodiment of a device for producing an exhaust-gas component, and

FIG. 5 shows an illustration of an arrangement of a multiplicity of exhaust-gas components in plan view.

FIG. 1 shows, overall, an exploded illustration of an exemplary embodiment of an exhaust-gas component 1, wherein FIG. 1a ) illustrates a multiplicity of—cross-sectionally—rectangular, in this case in particular square, exhaust-gas aftertreatment elements 3, which are arranged in a housing 5. Specifically, in this case, four cross-sectionally square exhaust-gas aftertreatment elements 3, which are preferably formed as ceramic catalyst substrates, are arranged relative to one another and in the housing 5 such that the arrangement of the exhaust-gas aftertreatment elements 3 is itself square, wherein in each case two exhaust-gas aftertreatment elements 3 are arranged adjacent to one another in two directions of the cross-sectional plane such that each edge of the altogether square arrangement is formed from two edges, arranged one behind the other or adjacent to one another, of the exhaust-gas aftertreatment elements 3. In the exemplary embodiment illustrated here, as viewed in the longitudinal direction, in each case only one exhaust-gas aftertreatment element 3 is provided, such that the arrangement itself, and the housing 5, ultimately also has a length of approximately one exhaust-gas aftertreatment element 3, preferably a slightly greater length.

The housing 5 engages around the exhaust-gas aftertreatment elements 3 arranged relative to one another. Said housing 5 itself has a rectangular, in this case square, cross section and is divided, along a diagonal D arranged here, into two housing parts, specifically into a first housing part 7 and a second housing part 9.

The housing 5 and the exhaust-gas aftertreatment elements 3 together—preferably with at least one compression mat—form a compression unit 10. FIG. 1b ) illustrates an external housing 11 in which the housing 5 can be arranged under compressive stress in the assembled state. Here, in the assembled state, the housing parts 7, 9 are preferably forced against one another or toward one another at mutually adjacent housing edges 13, 15. Here, such adjacent housing edges 13, 15 exist in particular on both sides of the diagonal D, wherein in this case only the housing edges 13, 15 facing toward the viewer are visible, and wherein the opposite housing edges—as viewed along the diagonal D—are concealed in the view of FIG. 1a ).

Here, the housing parts 7, 9 are formed as—cross-sectionally—L-shaped sheet-metal elements, in particular as angularly folded sheet-metal shell halves. Here, an edge length, measured in the cross-sectional plane, of housing edges 17, 17′ perpendicular to the first housing edge 13 and to the second housing edge 15 is smaller than a length of an arrangement edge, bearing against the housing edges 17, 17′ in the assembled state, of the arrangement of the exhaust-gas aftertreatment elements 3 in the stress-relieved state, such that the adjacent housing edges 13, 15 have a certain spacing to one another in the stress-relieved state. It is possible for said spacing to be closed in the compressed state. It is likewise also possible for the housing parts to be dimensioned such that the spacing between the adjacent housing edges 13, 15 is duly decreased, but not reduced to zero, even in the compressed state.

The housing parts 7, 9 each have, at their housing edges 13, 15 which are mutually adjacent in the assembled state, positive-locking elements 19, 19′ which are configured to engage one into the other in the assembled state. Here, the positive-locking elements 19, 19′ have teeth which—as illustrated in FIG. 1a )—engage one into the other in the assembled state. In this way, the housing parts 7, 9 can be easily aligned relative to one another and provisionally fixed to one another.

The housing parts 7, 9 have face-side, inwardly directed, preferably inwardly bent or beaded housing flanges 21, which serve in particular for the pressing of the housing 5 into the external housing 11.

Furthermore, the housing parts 7, 9 have in each case one pull-out element 23, wherein the pull-out elements 23 are formed here as eyelets which are fastened in each case in a bending edge of the L-shaped housing parts 7, 9, in particular are welded in the bending edge.

The housing parts 7, 9 are preferably bent from thin sheet metal, wherein a sheet-metal thickness of the housing parts 7, 9 is preferably 1 mm.

The external housing 11 is preferably also formed from bent sheet-metal parts, which are preferably welded to one another in the region of weld seams 25.

The external housing 11 has external flanges 27 which are directed outward at a face side and which have flange positive-locking elements 29. The flange positive-locking elements 29 are composed in each case of a sequence of mutually adjacently arranged projections and recesses, which are arranged on the external-housing flanges 27 such that adjacent external-housing flanges 27 of two mutually adjacently arranged external housings 11 of identical form can engage with their projections and recesses one into the other in positively locking fashion. The projections preferably have fastening bores 31 which serve for the fastening, for example screw connection, of the external housing 11 and thus also of the entire exhaust-gas component 1 to a superordinate exhaust-gas aftertreatment device. For the sake of better clarity, here, only one fastening bore is denoted by the reference designation 31.

The external flanges 27 are preferably produced by folding of the metal sheets that form the external housing 11. Here, apertures initially remain in the four corners of the face side, which apertures are preferably filled with in each case one preferably rectangular, in particular square, sheet-metal piece 32 in order to close the external flanges 27 in the circumferential direction. The four sheet-metal pieces 32 are preferably welded to the external flanges 27 and thus form, as a result, a part of the finished external flanges 27.

FIG. 2 shows an illustration of an assembly of the exhaust-gas component 1 as per FIG. 1. Identical and functionally identical elements are denoted by the same reference designations, such that in this respect, reference is made to the description above. Here, in particular, the housing 5 with the exhaust-gas aftertreatment elements 3 has been inserted, in particular pressed, into the external housing 11, wherein said housing is arranged under compressive stress in the external housing 11. It is also illustrated here that wire mesh elements 33 may also be arranged on the outside of the external housing 11, which wire mesh elements serve for the mounting of the external housing 11 in a superordinate exhaust-gas aftertreatment device.

In the assembled state, the housing parts 7, 9 are preferably welded to the external housing 11 in the region of the pull-out elements 23, in particular by means of in each case one weld seam preferably 50 mm in length.

Also visible on the external housing 11 are slots 35, wherein the external housing 11 has a slot 25 of said type in particular on each of its four sides, wherein, in FIG. 2, owing to the selected view, only two of said slots 35 are visible. A cross-shaped holding bracket (not illustrated), composed in particular of sheet-metal, is preferably held—preferably in non-positively locking, positively locking or cohesive fashion, preferably by welding—in said slots, wherein the cross-shaped holding bracket arranged in the external housing 11 serves as a stabilizing support structure for the external housing 11.

FIG. 3 shows an illustration of the arrangement of exhaust-gas aftertreatment elements 3 with a multiplicity of compression mats 37, as is preferably provided in the exemplary embodiment as per FIGS. 1 and 2. Identical and functionally identical elements are denoted by the same reference designations, such that in this respect, reference is made to the description above. In the exemplary embodiment illustrated here, compression mats 37 are arranged between the individual exhaust-gas aftertreatment elements 3 and between each exhaust-gas aftertreatment element 3 and the housing 5. Said compression mats serve firstly for sealing off the arrangement and secondly for providing compressibility and/or elasticity of the compression unit 10 which exceeds the elasticity of the housing parts 7, 9.

In particular, in the exemplary embodiment illustrated here, a multiplicity of identical compression mats 37 is provided, wherein each of the compression mats has at least one slot 39, wherein said slot 39 extends preferably centrally from an outer edge or mat edge of a compression mat 37 as far as approximately a center or center of gravity of the compression mat 37. The slot 39 is thus formed as a central slot. At least two of the compression mats 37 are fitted one into the other by way of their slots 39. These are in particular compression mats which are not illustrated in FIG. 3, because they are concealed, and which are arranged in a cross-shaped manner within the arrangement of, and between, the exhaust-gas aftertreatment elements 3. Said compression mats are preferably of identical form, but are aligned oppositely in terms of their orientation, such that they can engage one into the other by way of their central slots and can thus form a cross-shaped arrangement of two mutually perpendicular compression mats 37.

In each case one further compression mat 37 is arranged on each outer side of the arrangement of the exhaust-gas aftertreatment elements 3, such that the arrangement illustrated here has a total of six compression mats 37, specifically two internally situated compression mats 37 arranged in a cross-shaped manner and four laterally arranged compression mats 37, two of which face toward the viewer in this case and are thus visible. The compression mats 37 preferably each have, in addition to the central slot 39, two lateral recesses 41, in the region of which an outer edge or mat edge of the compression mats 37 is set back slightly, wherein the recesses 41 extend, in particular as recesses which are open at the edge on two sides, from a lower edge 43 as far as approximately the center of a side edge 45 accommodating the respective recess 41. The remaining region of the extent of the side edge 45 thus forms, as it were, a projection 47 as viewed relative to the recess 41. The laterally arranged compression mats 37 are now aligned in each case in an alternatingly reversed manner with respect to one another, that is to say have alternatingly different orientations, wherein the projections 47 engage into the recesses 41 in each case. It can additionally also be seen that the projections 47 of the central compression mats 37 arranged in a cross-shaped manner engage into the central slots 39 of the laterally arranged compression mats 37. In this way, a stable assembled arrangement of compression mats 37 is provided, which can be realized in a simple manner by placing the compression mats 37 on and plugging them together. Therefore, no complex wrapping of individual exhaust-gas aftertreatment elements 3 is necessary.

FIG. 4 shows a schematic illustration of a device 49 for carrying out a method for producing the exhaust-gas component 1, in particular the exhaust-gas component 1 as per the exemplary embodiment illustrated in FIGS. 1 to 3. The device 49 has a holding device 51 which has a support surface 53 which is L-shaped as viewed in the cross section of a compression unit 10 arranged on the holding device 51. Said support surface is formed, in the exemplary embodiment of the holding device 51 illustrated here, by two support elements 55, such that the support surface 53 is in this case ultimately of two-part form. The support elements 55 are in turn held on a bearing frame 57.

The L-shaped support elements 55 and thus at the same time the support surface 53 are oriented such that a knee of the L shape points downward in a vertical direction.

The device 49 has at least one stop plate, formed as a stop element 58, for the alignment of the housing parts 7, 9, of the exhaust-gas aftertreatment elements 3 and/or of the compression mats 37.

The holding device 51 furthermore has at least one, in this case specifically two, clamping brackets 59, which are configured to engage around the compression unit 10 and to introduce a compression force into the compression unit 10. Here, the clamping brackets 59 have in each case two clamping bracket parts, specifically in each case one first clamping bracket part 61 and one second clamping bracket part 63, wherein the clamping bracket parts 61, 63 can be braced together and thus generate a compression force which is directed inward, that is to say in particular into an interior that is engaged around by the clamping bracket parts 61, 63.

To produce the exhaust-gas component 1, the first clamping bracket parts 61 are firstly arranged on the support surface 53. Subsequently, the first housing part 7 is placed onto the first clamping bracket parts 61, in particular such that said first housing part abuts against the stop element 58. Then, the compression mats 37 and the exhaust-gas aftertreatment elements 3 are arranged on the first housing part 7 so as to form a—cross-sectionally—rectangular, preferably square arrangement. Thereafter, the second housing part 9 is placed onto said arrangement of the exhaust-gas aftertreatment elements 3 and of the compression mats 37, whereby the compression unit 10 is produced. Here, the positive-locking elements 19 of the housing parts 7, 9 serve for the alignment of said housing parts relative to one another. The second clamping bracket parts 63 are now placed onto the compression unit 10 thus formed, and said second clamping bracket parts are braced with the first clamping bracket parts 61, such that the clamping brackets 59 are formed and a compression force is applied to the housing parts 7, 9 such that the compression unit 10 is compressed.

The compression unit 10 with the clamping brackets 59 can subsequently be removed from the holding device 51. The compression unit 10 is then finally pressed of a press device (not illustrated here) into the external housing 11, wherein a pressing force is preferably applied to the face-side, inwardly directed housing flanges 21. It is possible here for the compression unit 10 to be pressed out of the clamped clamping brackets 59 and simultaneously pressed into the external housing 11. It is however also possible for the clamping brackets 59 to be—in particular successively—released as the compression unit 10 is pressed into the external housing 11.

FIG. 5 shows an illustration of an arrangement of a multiplicity of exhaust-gas components 1 as per the exemplary embodiment illustrated in FIGS. 1 to 3 in plan view. Identical and functionally identical elements are denoted by the same reference designations, such that in this respect, reference is made to the description above.

It can be seen here that exhaust-gas components 1 of identical form and arranged adjacent to one another engage one into the other by way of the flange positive-locking elements 29 of the external-housing flanges 27, such that the exhaust-gas components 1 can be arranged in a very structural-space-saving and at the same time—owing to the recesses formed on the external-housing flanges 27—also material-saving manner. At the same time, the positive-locking elements 29 engaging one into the other stabilize the arrangement of the exhaust-gas components 1. These are preferably arranged in, in particular fastened to or in, an exhaust-gas housing (not illustrated) of a superordinate exhaust-gas aftertreatment device. Here, it is possible in particular for the exhaust-gas components 1 to be screwed into the exhaust-gas housing by means of the fastening bores 31.

Also visible in FIG. 5, owing to the face-side view, are the central compression mats 37 arranged in a cross-shaped manner between the exhaust-gas aftertreatment elements 3.

Altogether, it can be seen that, with the exhaust-gas component 1, the method for the production thereof and the device for carrying out the method, an optimized rectangular, preferably square, arrangement of exhaust-gas aftertreatment elements 3 can be provided. Here, structural space advantages are achieved in an entire exhaust-gas aftertreatment installation owing to the simple, compact and at the same time flexible arrangement of rectangular, in particular square, exhaust-gas aftertreatment elements 3, which are easily exchangeable. Furthermore, damage to the exhaust-gas aftertreatment elements 3 during the assembly process is prevented in an effective manner. 

1-15. (canceled)
 16. An exhaust-gas component, having a cross-sectionally rectangular arrangement composed of at least one cross-sectionally rectangular exhaust-gas aftertreatment element; a housing that engages around the cross-sectionally rectangular arrangement, wherein the housing has a rectangular cross section and is divided, along a diagonal of the cross section, into two housing parts; and an external housing, the housing being arranged under compressive stress in the external housing.
 17. The exhaust-gas component according to claim 16, wherein the two housing parts are forced toward one another under stress at mutually adjacent housing edges.
 18. The exhaust-gas component according to claim 16, wherein the two housing parts are formed, in cross-section, as L-shaped sheet-metal elements.
 19. The exhaust-gas component according to claim 18, wherein an edge length, measured in a cross-sectional plane, of a housing edge of at least one of the two housing parts is smaller than a length of an arrangement edge, bearing against the housing edge in an assembled state, of the arrangement of the at least one exhaust-gas aftertreatment element in a stress-relieved state.
 20. The exhaust-gas component according to claim 16, wherein the two housing parts have, at housing edges which are mutually adjacent in an assembled state, positive-locking elements configured to engage one another in the assembled state.
 21. The exhaust-gas component according to claim 16, further comprising at least one compression mat arranged between the at least one exhaust-gas aftertreatment element and the housing and/or between at least two exhaust-gas aftertreatment elements.
 22. The exhaust-gas component according to claim 16, further comprising a plurality of identical compression mats, wherein each compression mat has at least one slot.
 23. The exhaust-gas component according to claim 22, wherein at least two of the compression mats are arranged so as to be fitted into one another.
 24. The exhaust-gas component according to claim 16, wherein the two housing parts have face-side, inwardly directed housing flanges.
 25. The exhaust-gas component according to claim 16, wherein the external housing has external-housing flanges directed outward at a face side and which have flange positive-locking elements.
 26. A method for producing an exhaust-gas component, comprising the steps of: providing a cross-sectionally L-shaped first housing part; arranging at least one cross-sectionally rectangular exhaust-gas aftertreatment element on the first housing part to form a cross-sectionally rectangular arrangement; placing a cross-sectionally L-shaped second housing part on to the arrangement to produce a compression unit; applying a compression force to the housing parts so that the compression unit is compressed; and pressing the compression unit under compressive stress into an external housing.
 27. The method according to claim 26, including arranging at least one compression mat between at least two exhaust-gas aftertreatment elements and/or between at least one exhaust-gas aftertreatment element and the housing formed by the first and the second housing parts.
 28. The method according to claim 26, including arranging the first housing part on a cross-sectionally L-shaped support surface of a holding device.
 29. The method according to claim 26, wherein the compression force is applied to the housing parts by clamping brackets clamped around the compression unit.
 30. The method according to claim 26, wherein the pressing of the compression unit into the external housing is performed by applying a pressing force to face-side, inwardly directed housing flanges of the housing parts.
 31. A device for carrying out a method according to claim 26, comprising: a holding device that has a cross-sectionally L-shaped support surface; and at least one clamping bracket for applying a compression force to a compression unit of an exhaust-gas component to be produced.
 32. The device according to claim 31, wherein the at least one clamping bracket has a first clamping bracket part arrangeable on the support surface.
 33. The device according to claim 31, wherein the support surface has at least one recess for arrangement of the first clamping bracket part. 